Method of forming display package



United States Patent M U.S. CI. 53--29 5 Claims ABSTRACT OF THE DISCLOSURE Patented Dec. 23, 1969 which transforms the blank into a substantially U-shaped configuration open laterally outwardly to one side with an extending end wall. A product is pushed laterally into the partially formed package through its open side as it is moved along continuously. The extending end wall is then folded into position on its score as the partially erected package and product are moved along, whereupon the glue flap is adhered to the side wall to complete a A method of forming a display package whereby a cut This invention relates to the art of forming display packages. More particularly, it relates to a method of transforming a cut and scored cartonboard blank into a finished package by folding and forming the blank such that the article being packaged can be inserted into an open end whereupon subsequent folding and gluing steps are performed until the package is completed.

The present invention was particularly devised for the making of display packages of the type described in U.S. Patent 3,270,875, issued to Robert V. Burt on Sept. 6, 1966, and referred to herein as the Burt patent. The Burt patent is commonly owned by the assignee of the present application. In considering the package of the aforesaid Burt patent for commercial use, one of the first problems encountered was the lack ofasuitable method formaking such packages at acceptable speeds and with satisfactory efiiciencies to make it a practical and economic success. There was a need for a method that was adaptable to automation without any regard to the shape, rigidity, or configuration of articles being packaged. The absence of a suitable commercially available method for forming the display package of the Burt patent to meet the above requirements resulted in a need which was not satisfied until the invention of the present method.

It is an object of the present invention to provide a method of forming display packages whichis suitable for high speed automatic operation'at good efiiciencies such that a package of the type disclosed in the aforesaid Burt patent is commercially feasible.

Another object of the invention is the provision of a method for making a display package of the above mentioned kind in which the package is formed without using the article being packaged as a forming mandrel thereby allowing for great variety in the types of articles that can be packaged.

The nature and substance of the invention can be summarized as comprising a method of forming a completed package from a flat package blank which has been precut and scored by initially forming tubular support elements along one edge of the blank. The blank formed to this stage is then folded on two of its transverse scores frame structure around the product. The final steps in carrying out the formation of the package consist of folding and adhering the bottom closure flaps which project from the blank.

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the present invention, it is believed the invention will be better understood from the following description taken in connection with the accompanying drawings in which:

FIGURE 1 is a schemmatic perspective view illustrating the steps utilized in carrying out the method of the present invention.

FIGURE 2 is a plan view showing schematically the elements of an apparatus that can be employed in carrying out the method of the invention.

FIGURE 3 is an elevation, partially .in cross section, taken on the line 3-3 of FIGURE 2 showing other details of a mechanism for carrying out the method of the invention.

Referring now to the drawings, FIGURE 1 illustrates a stack 11 of packaging blanks which are fed in single file order through a sequence of manipulations or steps whereby finished packages are formed. The details of the individual blanks 12 which comprise the stack 11 are best illustrated in FIGURE 2 in which a plan view of the stack 11 is shown. The blanks 12 are, in fact, substantially similar to the blank illustrated in FIGURE 1 of the Burt patent cited above, and comprise side walls 13 and 14 and end walls 15 and 16, as well as a glue flap 17. The side and end walls are defined by a pair of spaced longitudinal scores 18 and 19, and a plurality of transverse scores 20, 21, 22 and 23.

Rim forming flaps 24, 25, 26 and 27 project laterally from one side of each of the side and end walls beyond the longitudinal score 18. The rim forming flaps may be suitably scored longitudinally so they can ultimately be folded into tubular support elements as the blank 12 is transformed into a package. Bottom closure flaps 28, 29, 30 and 31 project from the side and end walls beyond the longitudinal score 19.

Successive blanks 12 are taken from the bottom of the stack 11 and moved to a position where the rim forming flaps 24, 25, 26 and 27 are folded on their longitudinal scores and transformed into tubular support elements 32 along one edge of the blank alongside the longitudinal score 18. The cross section of the tubular support elements 32 may take any desired form. Preferably, the flaps 24-27 are provided with two longitudinal scores parallel to the score 18 so that the tubular support elements 28 are formed with a triangular cross section. This is not essential, however, as it is possible to form the flaps 24-27 into a cross section having an arcuate configuration whereby no scoring of the flaps is needed; or, it is possible to form these flaps into virtually any configuration that may be preferred for a given package. The formation of the tubular support elements 32 can be carried out 'by the apparatus described in US. Patent 3,398,660 issued on Aug. 27, 1968, to Howard N. Watrous, entitled Machine for Making Frame Blanks and for Thereafter Forming said Blanks Around an Article, said patent being commonly owned by the assignee of the present application.

The blank illustrated at the position 33 (in FIGURE 1) has the tubular support elements 32 formed and completed thereon. From this condition, it is then folded on the transverse scores 22 and 23 such that it assumes a U-shaped configuration as at position 34 in which it is suitable for receiving the product laterally through the open side. The side of the U-shaped partially erected package remains open as a consequence of the end wall 15 which remains in a common plane with the side wall 13.

The product to be packaged preferably comprises a stack of facial tissues 35 shown in the lower right portion of FIGURE 1. It will be understood, however, that the nature of the product being packaged is immaterial to the practice of the method and, as previously stated, it may be of any material, shape, configuration or degree of rigidity. In order to make the display package of the aforesaid Burt patent, the product 35 is first placed placed upon the cover member 36 whereupon the assembled combination 37 is placed into a position where it can be readily inserted endwise into the U-shaped packaging blank as at position 34. It will be understood, however, that the nature of the product being packaged is immaterial to the practice of the method and, as previously stated, it may be of any material, shape, configuration or degree of rigidity. In order to make the display package of the aforesaid Burt patent, the product 35 is first placed upon the cover member 36 whereupon the assembled combination 37 is placed into a position where it can be readily inserted endwise into the U-shaped packaging blank as at position 34.

It will be noted that the package is, in effect, formed in its inverted position as the tubular support elements 32 are in the lowermost position when the blank in position 34 is prepared to receive the assembled c mbination 37. This has been found to be the preferred method of assembly because the tubular support elements 32 arethen in a position to support the combination 37 comprising the product and cover member as subsequent package forming steps are carried out.

The assembled combination 37 is moved laterally into the open end of the U-shaped blank, as illustrated at position 38. The end panel 15 is then pivoted on the transverse score 21 to close the end of the package. An adhesive is applied to the glue flap 17 which is then preferably adhered to the inner surface of side Wall 14 to complete the side walls around the product (see p sitions 39 and 40 in FIGURE 1). Subsequently, the bottom closure flaps 28, 29, 30 and 31 are sequentially folded, lapped and adhered to complete the package as at position 41.

FIGURES 2 and 3 illustrate schematically an apparatus that can be used to carry out the method of the invention and a detailed description thereof will be made to assist in understanding the invention. After folding and forming the tubular support elements 32, the blank at position 33 is folded on the score lines 22 and 23 by feeding from position 33 between four co-acting pairs of properly curved folder bars 42, 43, 44 and 45 such that it is made into the U-shaped configuration of position 34 as it is moved into the conveying pocket 46. Each of the pairs of folder bars is composed of two spaced bars such that the blank is moved between the bars of each pair. The pairs 43 and 44 cause the blank to be folded on the score 22 and 23; whereas, the pairs 42 and 45 assisting in folding the side walls 13 and 14 into right angle con- 4- figuration with respect to the end wall 16. The conveying pockets 46 support the U-shaped carton of position through subsequent assembly, folding and gluing operations.

The product 35 and cover member 36 which comprise the assembled combination 37 are supported by the support members 46 which are moved a ong in unison with the conveying pockets 46. After each successive U-shaped package blank is placed in a c nveying pocket 46, a corresponding product and cover member combination 37 is moved laterally into the open end by means of the pusher member 48 which slides the product and cover combination 37 into place as the conveying pocket 46 and cooperating support member47 move forward in unison.

After the product and cover member are in the partially formed package, the end wall 15 is folded on the transverse score 21 by means of the folder guides 49 and 50. An applicator 51 applies an adhesive to the flap 1 7. The tucker member 52 then folds the side wall 15 such that the flap 17 bears against the projecting finger 53 of the guide and presser member 54. Further movement of the partially completed package causes the guides 49 and 50 to tuck the flap 17 into its assembled position where it is superposed with the inner surface of the side wall 14.

On further movement of the assembly, the roller 55 at the other end of the member 54 engages a cam 56. This causes the member 54 to pivot on the shaft 57 such that the face 58 bears inwardly on the side Wall 14. This latter action provides a sealing pressure between the contacting surfaces of the wall 14 and flap 17 in order that a strong adhesive seal is formed therebetween.

The remaining steps of folding the bottom closure fiaps 28, 29, 30, and 31 is carried out by conventional folding elements. Adhesive is applied to the contacting surfaces whereupon the closure flaps are adhesively secured to complete the assembly of the display package.

While particular embodiments of the invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention and it is intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

What is claimed as new is:

1. A method of forming a display package from a fiat package blank having a pair of spaced longitudinal scores and a plurality of parallel transverse scores which divide the blank into adjoining side walls, end walls and a glue flaps, there being a rim forming flap extending from the longitudinal score at one side of each side wall and end wall comprising the steps of (a) folding the rim forming flaps into tubular support elements and adhering said elements along the upper edge of the side walls and end walls adjacent one of said longitudinal scores,

(b) folding said blank on two of said transverse scores which separate adjoining side and end Walls to transform the flat blank into a blank of essentially U- shaped configuration such that one pair of adjoining side and end walls remain in a common plane,

(c) placing the U-shaped blank into a position such that the end of the U-shaped blank which remains open faces to one side,

((1) inserting a product laterally into the U-shaped blank through said one side,

(e) folding said U-shaped blank on the transverse score separating the side and end walls left in a common plane when forming said U-shaped blank to completely enclose the product within the package, thereaftilr adhering the glue flap of said blank to one side wa 2. A method of forming a display package as claimed in claim 1 wherein said fiat blank is folded into a U- shaped blank such that the tubular support elements are lowermost in the partially erected package.

3. A method of forming a display package as claimed in claim 2 including the step of adhering the glue flap on the inner surface of the side wall to complete the package blank around the product.

4. A method of forming a display package as claimed in claim 3 including the step of stacking the product on a cover member prior to inserting said product into said blank and thereafter inserting the combined product and cover member into the blank through said open end.

5. A method of forming a display package as claimed in claim 4 wherein said package blank includes bottom closure flaps projecting from the longitudinal score opposite the rim forming flaps, said method including the step of folding and adhering the bottom closure flaps to complete the package.

References Cited UNITED STATES PATENTS 10 THERON E. CONDON, Primary Examiner E. F. DESMOND, Assistant Examiner 

